Battery pack for sterile transfer battery container

ABSTRACT

A rechargeable battery pack for a surgical powered instrument. The battery pack is an assembly of individual cylindrical battery cells and has its electrical terminals in the form of sockets recessed within the body of the pack in the interstices between the cells. The terminal sockets are adapted to receive elongated plugs and enable the pack to be handled while minimizing the risk of shorting.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention generally relates to battery operated surgicalpowered instruments. More particularly, the invention relates to batterypacks which enable the use of non-sterile rechargeable batteries withsterile surgical instruments.

[0003] 2. Description of the Prior Art

[0004] In order to enable the use of rechargeable non-sterile batteriesin sterile surgical instruments, users employ a known “sterile transfer”technique. While possibly known by other names, this technique generallyentails the sterilization and use of a sterile battery container to beattached to a sterile powered instrument. The sterilized container isheld in a sterile field (by a scrub nurse, for example) and is shieldedby a sterile shroud. A non-sterile, charged battery (held by acirculating nurse, for example) is placed into the sterilized containerwith care so as not to contaminate the already sterilized container. Theshroud is then removed by the circulating nurse and the sterilizedcontainer is closed by the scrub nurse and attached to the instrument.The container hermetically encloses the battery and has its own exteriorterminals which are connected to the battery terminals and through whichthe instrument is powered.

[0005] The battery used in a sterile transfer container is generally abattery pack comprising a plurality of individual battery cells wiredand bound together in one unit. The terminals of the cells are connectedin series and to the terminals of the battery pack. As used herein, theterm “battery” will be understood to include a battery pack.

[0006] Prior art battery packs generally have terminal contacts whichare surface mounted and engageable by contiguous engagement with anothersurface contact in the device with which the battery pack is designed tooperate. The surface contacts are designed to be pressed toward eachother, essentially pushing in opposite directions along an imaginaryline passing through both contacts at the point at which they arecontiguous. Sometimes a spring force is designed into the engagement toenhance the force with which the terminal contacts press against thedevice contacts.

[0007] Surface contacts are subject to vibration in powered surgicalinstruments and this may increase wear and affect performance. Also,surface contacts may subject a battery to risk of shorting if thebattery terminals inadvertently connect conductive materials beforebeing put into the intended instrument.

[0008] Additionally, surface contacts necessarily increase the size ofthe battery and/or battery/instrument combination. This occurs simplybecause of the necessity of providing relatively massive contacts and/orspring mechanisms to maintain a secure connection during use.

[0009] Accordingly, it is an object of this invention to produce abattery pack with increased security from failure.

[0010] It is also an object of this invention to produce a battery packhaving a reduced risk of shorting across its terminals.

[0011] It is an additional object of this invention to produce a batterypack which has a smaller height to minimize the size of the steriletransfer container or instrument into which the battery pack is designedto fit.

SUMMARY OF THE INVENTION

[0012] These and other objects of this invention are achieved by thepreferred embodiment disclosed herein which is a battery pack comprisinga plurality of individual battery cells assembled into a predeterminedconfiguration having interstices between the individual calls.Electrically positive and negative socket means are inserted intoselected ones of the interstices, each socket means is adapted tomateably engage a plug. In one aspect of the invention the individualbattery cells are cylindrical and the axes of the cells are all alignedwith each other. The socket means may comprise a pair of leaf springcontact members adapted to receive therebetween a plug.

[0013] In another aspect the invention comprises a method of producing abattery pack in such away as to use the interstices between cylindricalcells to house electrical contacts. The method comprises the steps ofassembling a plurality of cylindrical battery cells so that theirrespective axes are aligned and their cylindrical surfaces arecontiguous to thereby form at least two parallel channels betweenpredetermined ones of the cells. The method further comprises using eachof the two parallel channels to receive therein respective positive andnegative electrical contacts, wiring the electrical contacts to thebattery cells to form a battery pack and securing battery cells togetherto form the battery pack.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a bottom perspective view of an assembled battery pack,constructed in accordance with the principles of this invention, as itrelates to a sterile transfer container designed to receive the batterypack.

[0015]FIG. 2 is a top perspective view of the battery pack of FIG. 1showing the battery pack partially assembled.

[0016]FIG. 3 is a view of FIG. 2 at a different stage in the assembly ofthe battery pack.

[0017]FIG. 4 is an exploded view of a portion of FIG. 3.

[0018]FIG. 5 is a top perspective view of a battery pack at anotherstage of its assembly.

[0019]FIG. 6 is a bottom perspective view of a battery pack at anotherstage of its assembly.

[0020]FIG. 7 is a bottom perspective view of a fully assembled batterypack.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0021] Referring to FIG. 1, battery pack 10 is designed to fit insterile transfer container 12. Container 12 has a hollow body 14 with aclosed distal (top) end 16, and open proximal (bottom) end 18. Thecontainer is designed to be closed with cover 20, hinged at 22, andlocked by locking mechanism 24. Details regarding sterile transfercontainer 12 are described in co-pending U.S. patent applicationentitled Sterile Transfer Battery Container assigned to the assigneehereof and incorporated by reference herein. Battery pack 10 has top andbottom surfaces 30 and 32, respectively, and has a peripheral wallsurface 34.

[0022] As best seen in FIGS. 2 through 6, battery pack 10 is made up ofa plurality of individual rechargeable battery cells 40. Each cell is inthe form of a cylinder which has an axis 42, a cylindrical wall 44 andopposing positive and negative electrical terminals 46 and 48. The cells40 are arranged in a conventional manner with their axes 42 aligned,their cylindrical walls 44 in contiguity and their electrical terminalsalternating on adjacent cells. The alternation of the terminalsfacilitates wiring the cells in series by connecting straps 50, spotwelded end tabs 50A and 50B, and fuse 51 in a conventional manner, asbest seen in FIGS. 5 and 6. Wires 52A and 52B connect the fuse 51 inseries between tabs 50A and 50B spot-welded to the bottoms of adjacentbatteries. In prior art battery packs of this type the terminals of theindividual cells are connected to surface mounted electrical terminals(not shown) secured to some exterior surface of the battery pack. Aswill be understood below, the invention disclosed herein utilizes uniqueand novel electrical terminals.

[0023] While cells 40 may be arranged in a cluster in a variety of waysto conform to the devices with which battery pack 10 is to be used, inthe preferred embodiment the cells are arranged as shown in the drawingsin three parallel rows A, B and C. Rows A and B have three cells each,side by side, and row C has two, nested adjacent the cells of row B andnot side by side. The axes of the cells in rows A and B are arranged ina rectangular pattern. Each cell may be, for example, a nickel cadmiumor nickel metal hydride rechargeable cell with a rating of 1.2 volts percell, producing an eight cell battery pack with a rating of 9.6 volts.Other ratings could be produced with a different number of cells ordifferent types (lithium ion, etc.).

[0024] Referring to FIG. 2, it will be noted that the contiguousarrangement of cells in parallel rows, side by side, makes thecylindrical walls 44 create channels 52 between any four adjacent cellsin rows A and B with their axes arranged at the corners of a square.Each channel is as long as the length of the individual cells and itscross-section is generally in the shape of a square having inwardlycurved sides. Each channel is fitted with an electrically insulated,hollow electrode sleeve or retainer 54 having an exterior surface 56conforming to its respective channel 52 and an interior surface 58.Electrode retainers 54 are inserted into channels 52 and retained byfrictional engagement with cylindrical walls 44. In the preferredembodiment, interior surface 58 has a square cross-section and enclosesa cavity 60 within each retainer 54. Each cavity 60 is adapted toreceive, by frictional engagement preferably, an electrically conductiveterminal contact 62 to thereby create an electrical socket 63. Eachcontact 62 has a pair of opposed leaf spring members 64 and 65, and asupport member 66, all riveted together by rivet 68. Leaf spring members64 and 65 are assembled as shown in FIG. 4 so that their opposedcurvatures create a central point or gap 70 at which members 64 and 65are either in contact or very close to each other. Support member 66 isused to connect leaf spring members 64, 65 to the terminals of twoindividual cells as best seen in FIG. 6. Reinforcing plugs 71 areinserted into the bottom of each retainer 54 and may be held in place byfrictional engagement with the interior surface 58, by adhesive or byother suitable means. As explained below, plugs 71 keep contacts 62 frombeing pushed out of retainers 54 when a plug is engaged with socket 63.

[0025]FIGS. 5 and 6 show top and bottom perspective views, respectively,of a completely wired battery pack. At this stage of the assembly onlyminor additional steps are necessary to complete the fabrication ofbattery pack 10 to the final state shown in FIGS. 1 and 7. A plastic orother insulating end plate or covering 80 is used to cover the bottom ofthe cell assembly seen in FIG. 6. End plate 80 has, on its innersurface, one or more recesses (not shown) to receive and protect fuse 51and other components. A similar plastic or other insulating end plate 82is used to cover the top of the cell assembly seen in FIG. 5. End plate82 has two apertures 84 and 86 to allow plug access to positive andnegative sockets 63. The cell assembly shown in FIGS. 5 and 6, and theend plates 80 and 82 are then wrapped in an outer covering 88. In thepreferred embodiment covering 88 is shrink-wrap material. A handle 90 offlexible cloth or other material may be secured to the bottom 32 of thebattery pack to facilitate its removal from container 12.

[0026] It will be understood that elongated (flat or round) positive andnegative plug members, such as plug member 92 seen in FIG. 1, can beinserted into the point/gap 70 through the open socket end 63 of eachcavity 60, thereby establishing an electrical connection between theplug member 92 and the recessed contact 62. Only one plug 92 is seen inFIG. 1, but it will be understood that another plug is present. Similarplugs can be used on battery chargers or other devices with whichbattery pack 10 is to be connected.

[0027] As best seen in FIG. 7, because of the recessed configuration ofthe electrical contacts 62, battery pack 10 has a smooth, unobstructedbottom surface 30 which enables it to be placed on a metal surface orelsewhere without risking shorting the battery pack. Battery packshaving different numbers of cells or cells arranged in different waysmay produce channels of different cross-sections. However, retainers 54may be produced in other cross-sections and contacts 62 may be producedin other shapes so that the principles of this invention may be appliedto any other battery cell configuration. Basically, the interstices ofthe cell assembly are used to accommodate electrical sockets.

[0028] While this invention is explained herein in the context of abattery pack for use with sterile transfer techniques, it should beunderstood that the invention may be adapted to other techniques ordevices. With appropriate modifications, the invention may be used inall situations suitable for conventional batteries.

[0029] It will be understood by those skilled in the art that numerousimprovements and modifications may be made to the preferred embodimentof the invention disclosed herein without departing from the spirit andscope thereof.

What is claimed is:
 1. A battery pack comprising: a plurality ofindividual battery cells assembled into a predetermined configurationhaving interstices between the individual cells; and electricallypositive and negative socket means inserted into selected ones of saidinterstices, each socket means adapted to mateably engage a plug.
 2. Abattery pack according to claim 1 wherein said individual battery cellsare cylindrical and wherein the axes of said cells are all aligned witheach other.
 3. A battery pack according to claim 2 wherein saidinterstices between individual battery cells comprise elongated channelsand wherein said socket means are adapted to fit within selectedchannels.
 4. A battery pack according to claim 3 wherein said socketmeans comprise: a pair of leaf spring contact members adapted to receivetherebetween a plug; and securing means to secure said contact membersfrom movement relative to said channel.
 5. A battery pack according toclaim 4 further comprising a hollow, elongated retaining member adaptedto be received within said channel and adapted to retain said leafspring contact members within said retaining member.
 6. A battery packaccording to claim 5 wherein said hollow, elongated retaining member hasa proximal end, defining an opening for receiving a plug, and an opendistal end, further comprising a retaining plug adapted to preventmotion of said leaf spring contact members out of said open distal end.7. A battery pack comprising: at least three individual, cylindricalbattery cells aligned and arranged in a cluster, each of said cellshaving a predetermined length, an axis and a cylindrical wall, saidcells aligned and arranged with their respective axes parallel to eachother and with their cylindrical walls in contiguous engagement therebyforming a cavity between said cells in said cluster; a hollow, elongatedsleeve having a cross-section adapted to fit within said cavity incontiguous engagement with the cylindrical wall portions abutting saidcavity, said sleeve having an open distal end; a pair of elongatedelectrical contacts secured within said sleeve, said contactselectrically connected to said cells and adapted to receive a pluginserted through said open distal end of said sleeve; and securing meansto secure said cells in said cluster.
 8. A battery pack according toclaim 7 further comprising a retaining plug adapted to fit into and besecured at said proximal end of said sleeve for supporting said contactsagainst movement within said sleeve.
 9. A battery pack comprising: atleast six individual, cylindrical battery cells, each of said cellshaving a predetermined length, an axis, and a cylindrical wall, saidcells arranged into two parallel rows of three cells each, the axes ofthe cells in each row being parallel to each other and the cylindricalwall of each cell in each row being in contiguous engagement with thecylindrical wall of a cell in the other row to thereby form two parallelcavities between said parallel rows, said parallel cavities axiallyaligned with the axes of said cells; a hollow, elongated sleeve situatedin each said cavity, each sleeve having an open distal end and adaptedto fit within its respective cavity in contiguous engagement with thecylindrical wall portions abutting said respective cavity; a pair ofelongated electrical contacts secured within each sleeve, each pair ofsaid contacts adapted to receive an electrically conductive pluginserted through the open distal end of its respective sleeve;connection means electrically connecting each of said cells and saidelectrical contacts to make one of said pair of electrical contacts apositive terminal and the other one of said pair of electrical contactsa negative terminal; securing means to secure said cells in saidcluster.
 10. A battery pack according to claim 9 wherein said cells insaid parallel rows are side by side so that the axes of the cells arearranged in a rectangular pattern.
 11. A method of producing a batterypack comprising the steps of: providing a plurality of cylindricalbattery cells, each cell having an axis and a cylindrical surface;arranging said plurality of battery cells so that their respective axesare aligned and their cylindrical surfaces are contiguous to therebyform at least two parallel channels between predetermined ones of saidcells, each of said channels having a distal end and a proximal end;using each of said two parallel channels to receive therein respectivepositive and negative electrical contacts; enabling said positive andnegative electrical contacts to be engageable with respective positiveand negative plugs inserted into the distal ends of said parallelchannels; wiring each of said electrical contacts to said plurality ofbattery cells to form a battery pack; and securing said plurality ofbattery cells together to form the battery pack.
 12. A method accordingto claim 11 wherein the step of using further comprises: securing intoeach of said two parallel channels a pair of leaf spring electricalcontact members so that said members do not extend axially out of saidbattery pack beyond the cylindrical surfaces of said cells forming saidchannels.
 13. A method according to claim 12 further comprising thesteps of: applying an insulating covering to the ends of said pluralityof cells on the side of the battery pack adjacent to said distal ends ofsaid channels; and providing said covering with two aperturesrespectively aligned with said positive and negative electricalcontacts, said apertures being sufficient to enable electrical plugs tomateably engage said electrical contacts.